1

For questions : Recep Durna Problem 2: A flat steel part machined from a plate, having a rectangular cross-
Room : D-112/D-103 Phone: 5216 section and made of AISI 1050 CD steel will be subjected to load F, which
E-mail : rdurna@[Link] Date: 25/11/2025 fluctuates between 4kN and 10kN, in a working environment of 100°C. Determine
the minimum thickness of the part for an infinite operation life taking factor of
ME 307 – MACHINE ELEMENTS I
safety as 2 and reliability as 0.95 according to the modified Goodman line. All
TUTORIAL 8
“FATIGUE DESIGN CRITERIA” dimensions are in mm.

Problem 1: An idealized representation of a machine member is shown in the

figure. It is made of steel having a circular cross-section with machined finish. F
F
The member is subjected to fluctuating bending with maximum and minimum
values, 2M and -4M. Determine the maximum value of M for an infinite life
using a factor of safety of 2 and taking the reliability as 0.95. Use the modified 50
Goodman line. (Sy = 400 MPa, Sut = 550 MPa, all dimensions are in mm’s.) 125
t Rotated cross section

R25
A

A
Figure 2

Figure 1

METU – ME 307 Machine Elements I – Fall 2025

 2
Problem 3: The figure is a schematic drawing of a countershaft rotating at
constant velocity that supports two V-belt pulleys. For each pulley, the belt
tensions are parallel. The pulleys are mounted on the shaft with key and profiled
keyway arrangements. For pulley A consider the loose belt tension is 15% of
the tension on the tight side. An AISI 1030HR steel shaft of uniform diameter
is to be selected for this application. Find a safe diameter for the shaft taking
Bearing
the factor of safety and reliability as 3 and 99.9%, respectively. For profiled Bearing
keyway Kf =1.6 for bending and Kf =1.3 for torsion. All dimensions are in mm’s.

Figure 4

Problem 5: A machine component made up of SAE1050HR steel is designed

for finite life. In the first 20.104 cycles, the periodic loading on the part has
mean and alternating stresses of 80MPa and 120MPa, respectively. In the
following 50.103 cycles, both alternating and mean stresses have increased by
25%. Reliability is 99% and kb=0.85. Use the Manson’s rule in (a), (b) and (c).

Figure 3 After these loadings:

a) Determine the endurance limit of the part after the loadings given by
Problem 4: A car axle carries a load of 235 kN. The material is medium Modified Goodman criteria.
carbon forged steel. Its Brinell Hardness number is 179, the ultimate strength b) Estimate the remaining life of the part for 200MPa completely reversed
is 620 MPa and the yield strength is 500 MPa. All dimensions are in mm. loading.
a) Find the value of the factor of safety for infinite life at the center of the axle c) Estimate the maximum value of completely reversed stress if the part is to
as the car is proceeding along a smooth straight-level track. be loaded for 100000 cycles.
b) Estimate the expected life under a completely reversed stress of 200 MPa d) Repeat (b) using the Miner’s rule.
and 400 MPa separately.

METU – ME 307 Machine Elements I – Fall 2025

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Solution 1:
Surface Factor: ka =0.773 (from table 6-2 and equation (6-18) Machined surface,
There are two critical sections to be considered to determine the maximum Sut = 550 MPa). This value is applied for both the fillet and the hole.
value of M. One of them is the shoulder section with 3 mm radius and the other
is the cross-section with the ø3 mm hole. The former is a part of section carries 𝑎 = 3.04 𝑏 = −0.217
maximum moment on the thin section of beam and the latter is a hole. One may
think the end of the beam, but for just 25% length increase for moment arm, 𝑘𝑎 = 𝑎(𝑆𝑢𝑡 )𝑏 (6-19)
Radius increases 50% and so second moment of area will be around 5 times, so
end of the beam cannot be a weak spot Size Factor: The member is a non-rotating solid cylindrical part. Therefore, an
effective value for the diameter must be used for calculating kb. (Page 312-313
Analysis of the cross-section at A-A:
explains)
Since the mean stress of element (1) in Figure 1 is positive (in tension), it is
more critical than the element (2) in fatigue failure. Therefore, element on the
upper surface will be considered. 𝑑𝑒 = 0.37 ⋅ 𝐷 = 0.37 ⋅ 20 = 7.4𝑚𝑚 (from the table 6-3 in the 11th edition of
textbook or (6-23) of the same book)
Although modified Goodman is given as design criteria, it is well known that
empirical approximations of fatique life are not significantly precise between Then 𝑘𝑏 = 1.24(1000 ⋅ 𝑑(𝑚))−0.107 ≅ 1
different specimens and so there are additional calculations suggested.
Specifically, “6-9 Endurance Limit Modifying Factors” of 11th edition Loading factor: 𝑘𝑐 = 1 due to applied bending moment.
Shigley’s Mechanical Engineering Design suggested by Joseph Marin is used Reliability Factor: 𝑘𝑒 = 0.868 (for a reliability of 0.95)
for this course. Temperature Factor: 𝑘𝑑 = 1 (nothing mentioned)
Then, the endurance limit of the machine member can be calculated.
𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑘𝑒 𝑆𝑒′ (6-17) Putting everything together gives:

𝑘𝑎 =surface factor 𝑆𝑒 = 0.773 ⋅ 1 ⋅ 1 ⋅ 0.868 ⋅ 1 ⋅ 1 ⋅ 0.5 ⋅ 550𝑀𝑃𝑎 = 184.5 𝑀𝑃𝑎

𝑘𝑏 =size factor
𝑘𝑐 =loading factor
𝑘𝑑 =temperature modification factor 𝑀⋅𝑐 𝜋⋅𝑑 4
𝑘𝑒 =reliability factor The bending stress at the change of cross-section is 𝜎 = 𝐼
where 𝐼 = 64
and 𝑐 =
𝑆𝑒′ =rotary-beam test specimen endurance limit (Take as unmodified value) 𝑑
at the surface.
𝑆𝑒 =endurance limit at the critical location of a machine part in the 2
geometry and condition of use At this stage, bending force is not known so a symbolic calculation to equate with
Moreover, since infinite life is expected modified Goodman is necessary.
Then,
32 ⋅ 𝑀
𝑆𝑒′ = 0.5𝑆𝑢𝑡 𝜎= = 1.27 ⋅ 106 ⋅ 𝑀
𝜋 ⋅ 𝑑3
The modifying factors should be determined in order to find the endurance limit 𝜎𝑚𝑖𝑛 = −1.27 ⋅ 106 2 ⋅ 𝑀
of the machine member. 𝜎𝑚𝑎𝑥 = 1.27 ⋅ 106 4 ⋅ 𝑀

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Stress Concentration Factor where Kf is fatigue stress concentration factor and To remember values
this factor is critical here because of obvious radius given to the work piece.
𝑆𝑦 = 400𝑀𝑃𝑎 𝑆𝑒 = 184.5𝑀𝑃𝑎 𝑆𝑢𝑡 = 550𝑀𝑃𝑎 𝑛=2
𝑟/𝑑 = 0.15
} ⇒ 𝐾𝑡 ≅ 1.5 (Figure A-15-9, the formula sheet)
𝐷/𝑑 = 1.5 𝜎𝑎′′ = 37.9 𝑀𝑃𝑎 and ′′
𝜎𝑚 = 162.1 𝑀𝑃𝑎
q  0.8 (Figure 6.20, the formula sheet) 𝛼 = atan(𝜎𝑎′′ /𝜎𝑚
′′ )
= 13.2°
This leads to 𝐾𝑓 = 1.4
Since 90° > 𝛽 > 𝛼; failure will be due to fatigue. Therefore, fatigue failure criteria
𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛 should be used.
′
𝜎𝑚 = 𝐾𝑓 = 1.778 ⋅ 106 ⋅ 𝑀
2
𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 𝜎𝑎′ 𝜎𝑚
′
1
𝜎𝑎′ = 𝐾𝑓 = 5.32 ⋅ 106 ⋅ 𝑀 + =
2 𝑆𝑒 𝑆𝑢𝑡 𝑛

Stress concentration factor is used above. 5.32 ⋅ 106 ⋅ 𝑀 1.778 ⋅ 106 𝑀 1

+ =
184.5 ⋅ 106 550 ⋅ 106 𝑛

𝑀 ≅ 15.6 𝑁 ⋅ 𝑚

Analysis of the section with the hole:

The surface factor ka value will not change (ka =0.773).

The effective diameter for the size factor is d e = 0.37  D = 0.37  30 = 11 .1 mm

Then, from (6-19), kb = 0.96 (neglecting the hole area) for 7.62 ≤ 𝑑 ≤ 51𝑚𝑚
Reliability, temperature and miscellaneous effects factors remains the same
Figure 5 therefore kc = 1, kd = 1 𝑘𝑒 = 0.868 and kf = 1
At this point we need to check where we are in modified Goodman diagram. 𝑆𝑒 = 𝑘𝑎 ⋅ 𝑘𝑏 ⋅ 𝑘𝑐 ⋅ 𝑘𝑑 ⋅ 𝑘𝑒 ⋅ 𝑆𝑒′
Slope of the load line is
𝛽 = atan (𝜎𝑎′ /𝜎𝑚
′
) = 71.6 ° Then, 𝑆𝑒 = 0.773 ⋅ 0.96 ⋅ 0.85 ⋅ 1 ⋅ 0.868 ⋅ 0.5 ⋅ 550
The intersection point of the modified Goodman and the Yield lines is: 𝑆𝑒 = 150.5 𝑀𝑃𝑎
Solving
′′ ′′
𝑆𝑦 𝜎𝑎′′ 𝜎𝑚′′
1
𝜎𝑎 + 𝜎𝑚 = and + = for 𝜎𝑎′′ , 𝜎𝑚
′′
𝑛 𝑆𝑒 𝑆𝑢𝑡 𝑛

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 5
𝜎𝑎
From the figure A-15-11:
−𝑀
𝜎0 ≈ 𝑆𝑦
𝜋𝐷 3𝑑 𝐷2
− ℎ𝑜𝑙𝑒
32 6

For an element on the outer surface:

𝑆𝑒
−𝑀′ 𝑀′
𝜎≈ =
𝜋 ⋅ 303 3 ⋅ 302 2.2 ⋅ 10−6
𝜎𝑎′
−
32 6
𝜎𝑎′′ 𝛽
𝛼
−2𝑀
𝜎𝑚𝑖𝑛 =
2.2 ⋅ 10−6 0 ′
′′
𝜎𝑚 𝑆𝑦 𝑆𝑢𝑡 𝜎𝑚
𝜎𝑚

The stress concentration modifying factor should be recalculated for new Kt

value. The intersection point of the modified Goodman and the Yield lines is:

𝑑ℎ𝑜𝑙𝑒 3 Solving:
= = 0.1 ⇒ 𝐾𝑡 ≅ 2.25 (Figure A − 15 − 11)
𝐷 30 𝑆𝑦 𝜎𝑎′′ 𝜎𝑚
′′
1
𝜎𝑎′′ + 𝜎𝑚
′′
= and + = for 𝜎𝑎′′ , 𝜎𝑚
′′
𝑛 𝑆𝑒 𝑆𝑢𝑡 𝑛
𝐾𝑓 = 1 + 𝑞 ⋅ (𝐾𝑡 − 1)
To remember values
𝐾𝑓 = 1 + 0.8 ⋅ (2.25 − 1) = 2
𝑆𝑦 = 400𝑀𝑃𝑎 𝑆𝑒 = 150.5𝑀𝑃𝑎 𝑆𝑢𝑡 = 550𝑀𝑃𝑎 𝑛=2

′
𝜎𝑚𝑎𝑥 + 𝜎𝑚𝑖𝑛 2𝑀 𝜎𝑎′′ = 28.3 𝑀𝑃𝑎 and ′′
𝜎𝑚 = 171.7 𝑀𝑃𝑎
𝜎𝑚 = 𝐾𝑓 =
2 2.2 ⋅ 10−6
𝛼 = atan(𝜎𝑎′′ /𝜎𝑚
′′ )
= 9.36°
𝜎𝑚𝑎𝑥 − 𝜎𝑚𝑖𝑛 6𝑀
𝜎𝑎′ = 𝐾𝑓 =
2 2.2 ⋅ 10−6 Since 90° > 𝛽 > 𝛼 ; failure will be due to fatigue. Therefore fatigue failure criteria
shuld be used.
Slope of the load line is the same as in previous section. 𝜎𝑎′ 𝜎𝑚 ′
1
+ =
𝑆𝑒 𝑆𝑢𝑡 𝑛
𝛽 = atan (𝜎𝑎′ /𝜎𝑚
′
) = 71.6 °

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For the modified Goodman Line; Axial Stress:
𝑃
𝜎 = 𝐴 where 𝐴 = ℎ ⋅ 𝑡 and ℎ = 50𝑚𝑚. Then
𝜎𝑎′ 𝜎𝑚
′
1
+ = 𝑃𝑚𝑖𝑛 4 ⋅ 103 80 . 103
𝑆𝑒 𝑆𝑢𝑡 𝑛 𝜎𝑎𝑥,𝑚𝑖𝑛 = = =
6𝑀 2𝑀 1 ℎ ⋅ 𝑡 0.05 ⋅ 𝑡 𝑡
+ =
2.2 ⋅ 10−6 ⋅ 150.5 ⋅ 10 6 −6
2.2 ⋅ 10 ⋅ 550 ⋅ 10 6 2 𝑃𝑚𝑎𝑥 10 ⋅ 103 200 . 103
𝜎𝑎𝑥,𝑚𝑎𝑥 = = =
ℎ⋅𝑡 0.05 ⋅ 𝑡 𝑡
𝑀 = 25.3 𝑁 ⋅ 𝑚
The critical moment value obtained from the change of cross-section is lower Bending Stress:
than the value obtained from the analysis of the cross-section with the hole. For a rectangular cross section:
Therefore, the value of M should not exceed 15.6 N.m for infinite life. Section 3-18 gives basic relations
ℎ
Solution 2: 𝑟𝑛 = , ℎ = 50𝑚𝑚, r𝑖 = 25𝑚𝑚 and 𝑟𝑜 = 𝑟𝑖 + ℎ = 75𝑚𝑚
𝑙𝑛( 𝑟𝑜 /𝑟𝑖 )
F
The most critical section of the part is section A-A 𝑟𝑛 = 45.5𝑚𝑚
due to the high bending stress of the curved
125
geometry. Therefore the section A-A should be 𝑅 = 𝑟𝑖 + ℎ/2 = 50𝑚𝑚 and 𝑒 = 𝑅 − 𝑟𝑛 = 4.5𝑚𝑚
considered to determine the minimum thickness t.
The free body diagram of the part for the section Tension is more critical than compression for fatigue design. Additionally, the
A-A can be drawn. stress at the inner fiber is higher than the outer one. Therefore stress at the inside
A fiber of the curved part will be considered.
The unknown force P and moment M can be
calculated using static equilibrium equations. 𝑀⋅(𝑟𝑛 −𝑟𝑖 )
B P Bending stress at the inside fiber is 𝜎 = . Then the minimum and the
∑𝐹𝑥 = 0 ⇒ 𝑃 − 𝐹 = 0 ⇒ 𝑃 = 𝐹 𝐴⋅𝑒⋅𝑟𝑖
M ∑𝑀𝐵 = 0 ⇒ 𝐹 × (125 + 25) − 𝑀 = 0 maximum bending stresses can be calculated.
A ⇒ 𝑀 = 150 𝐹
𝑀𝑚𝑖𝑛 ⋅ (𝑟𝑛 − 𝑟𝑖 ) 600𝑁𝑚 ⋅ (0.0455 − 0.025) 2187 ⋅ 103
𝜎𝑏,𝑚𝑖𝑛 = = =
Then the minimum and the maximum force and moment can be written as: (ℎ ⋅ 𝑡) ⋅ 𝑒 ⋅ 𝑟𝑖 (0.05 ⋅ 𝑡) ⋅ 0.0045 ⋅ 0.025 𝑡

𝑃𝑚𝑖𝑛 = 4 ⋅ 103 𝑁, 𝑃𝑚𝑎𝑥 = 10 ⋅ 103 𝑁 𝑀𝑚𝑎𝑥 ⋅ (𝑟𝑛 − 𝑟𝑖 ) 1500𝑁𝑚 ⋅ (0.0455 − 0.025) 5467 ⋅ 103
𝜎𝑏,𝑚𝑎𝑥 = = =
𝑀𝑚𝑖𝑛 = 4 ⋅ 103 ⋅ 0.15 = 600𝑁𝑚 (ℎ ⋅ 𝑡) ⋅ 𝑒 ⋅ 𝑟𝑖 (0.05 ⋅ 𝑡) ⋅ 0.0045 ⋅ 0.025 𝑡

𝑀𝑚𝑎𝑥 = 10 ⋅ 103 ⋅ 0.15 = 1500𝑁𝑚 For AISI 1050 CD steel: 𝑆𝑢𝑡 = 590𝑀𝑃𝑎 and 𝑆𝑦 = 490𝑀𝑃𝑎
At section A-A, the part is subjected to both axial and bending stresses. The Then 𝑆𝑒′ = 0.5 × 𝑆𝑢𝑡 → 𝑆𝑒′ = 0.5 × 590 = 295 𝑀𝑃𝑎
maximum and the minimum values of these stresses can be obtained in terms
of thickness t. The modifying factors for the endurance limit of the part can be determined. The
procedure follows the same logic of the previous question.

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𝜎𝑏−𝑚𝑎𝑥 + 𝜎𝑏−𝑚𝑖𝑛 1 5467 ⋅ 103 2187 ⋅ 103
Surface Factor:𝑘𝑎 = 0.831 (from Table 6-2 and Equation 6-18 of 11th edition 𝜎𝑏−𝑚 = = ( + )
2 2 𝑡 𝑡
Shigley’s Mechanical Engineering Design textbook; Machined surface, Sut =
3830 ⋅ 103
590 MPa). =
𝑎 = 3.04 𝑏 = −0.217 𝑡
𝜎𝑏−𝑚𝑎𝑥 − 𝜎𝑏−𝑚𝑖𝑛 1 5467 ⋅ 103 2187 ⋅ 103
𝜎𝑏−𝑎 = = ( − )
𝑘𝑎 = 𝑎(𝑆𝑢𝑡 )𝑏 = 0.773 (6-18) 2 2 𝑡 𝑡
1640 ⋅ 103
Size Factor: The member is a non-rotating solid rectangular part. Therefore, an =
𝑡
effective value for the diameter must be used for calculating kb.
The effective diameter for a non-rotating part having rectangular cross-section
is d e = 0.808 ×(h ×t )1/ 2 (6-24) where t is unknown. Therefore the range of the
effective diameter can be assumed to find an appropriate size factor.

Assume that 7.62 𝑚𝑚 < 𝑑𝑒 < 51𝑚𝑚 , then

Stress Concentration Factor: There is no stress concentration effect. Therefore
𝑘𝑏 = 1.24𝑑−0.107 𝐾𝑓−𝑎𝑥𝑖𝑎𝑙 = 1 and 𝐾𝑓−𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = 1

This gives value around 0.81 to 1. Let’s assume 0.85 as it is expected to be close 1640 ⋅ 103 60000 1700 ⋅ 103
𝜎𝑎′ = 1 . 𝜎𝑏−𝑎 + 1 . 𝜎𝑎𝑥−𝑎 = + =
to maximum limit (51 mm) and check here later. For axial stress kb is 1. 𝑡 𝑡 𝑡
140000 3830 ⋅ 103 3970 ⋅ 103
𝜎𝑚 ′ = 𝜎𝑎𝑥−𝑚 + 𝜎𝑏−𝑚 = + =
Loading factor: For bending: 𝑘𝑐 = 1. For axial load 𝑘𝑐 = 0.85 𝑡 𝑡 𝑡
Temperature Factor:𝑘𝑑 = 1.03 (for T=100°C, from figure 2.17 or Equation 6-
26) Note that the load factors are taken into account during the determination of
Reliability Factor: 𝑘𝑒 = 0.868 (for a reliability of 0.95; Table 6-5) alternating stresses since the values for axial and bending cases are different.
Then the total bending and alternating stresses are
Then, the endurance limit of the machine member can be calculated.
𝑆𝑒 = 𝑘𝑎 ⋅ 𝑘𝑏 ⋅ 𝑘𝑐 ⋅ 𝑘𝑑 ⋅ 𝑘𝑒 ⋅ 𝑆𝑒′
Then 𝑆𝑒 = 0.773 ⋅ 0.85 ⋅ 0.868 ⋅ 1.03 ⋅ 1 ⋅ 295 = 173.9 𝑀𝑃𝑎

The mean and alternating stresses for axial and bending loading are (for ductile
material):
𝜎𝑎𝑥−𝑚𝑎𝑥 + 𝜎𝑎𝑥−𝑚𝑖𝑛 1 200000 80000 140000
𝜎𝑎𝑥−𝑚 = = ( + )=
2 2 𝑡 𝑡 𝑡
𝜎𝑎𝑥−𝑚𝑎𝑥 − 𝜎𝑎𝑥−𝑚𝑖𝑛 1 200000 80000 60000
𝜎𝑎𝑥−𝑎 = = ( − )=
2 2 𝑡 𝑡 𝑡

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𝜎𝑎 Solution of the above equation for t gives 𝑡 = 33𝑚𝑚 which is the minimum value
of thickness in order to have infinite life of operation.
𝑆𝑦
Assumption of the effective diameter should be checked.
1 1
𝑑𝑒 = 0.808(ℎ ⋅ 𝑡)2 = 0.808(50𝑚𝑚 ⋅ 33𝑚𝑚)2 = 32.8𝑚𝑚

𝑘𝑐 = 1.24𝑑−0.107 = 0.854
𝑆𝑒
𝜎𝑎′ Since 7.62 𝑚𝑚 < 32𝑚𝑚 < 51𝑚𝑚 and 𝑘𝑐 assumption is close to obtained value
of 𝑘𝑐 , the assumption is correct.
𝜎𝑎′′ 𝛽
𝛼
Solution 3:
0 ′
′′
𝜎𝑚 𝑆𝑦 𝑆𝑢𝑡 𝜎𝑚
𝜎𝑚 At first, one should perform the force analysis of the system. During operation,
torque on the shaft is steady, so does the torsional stress on the shaft. Also the forces
in y and z directions are steady. However, because of the rotation of the shaft
Slope of the load line is bending stresses on the shaft do change periodically.
𝜎𝑎′
𝛽 = tan−1 ( ′ ) = 23.18° T1 and T2 is found from the torque balance on the shaft (  T = 0 ) by using the
𝜎𝑚
relation between them:
The intersection point of the modified Goodman and the Yield lines is:
𝑑𝐴 𝑑𝐵
∑ 𝑇 = 0 : (𝑇2 − 𝑇1 ) = (270 − 50) = 220(0.15) = 33 𝑁. 𝑚
2 2
𝑆𝑦 𝜎𝑎 ′′ 𝜎 ′′ 1
𝜎𝑎 ′′ + 𝜎𝑚 ′′ = 𝑛
and 𝑆𝑒
+ 𝑆𝑚 =𝑛 It is given that force on the loose side of the pulley is 15% of the force on the
𝑢𝑡
tight side. Knowing T2>T1:
To remember values
𝑆𝑦 = 490𝑀𝑃𝑎 𝑆𝑒 = 173.9𝑀𝑃𝑎 𝑆𝑢𝑡 = 590𝑀𝑃𝑎 𝑛=2 dA
(T2 − 0.15T2 ) = 33 N ⋅ m
2
33 N. m
𝜎𝑎′′ = 20.9 𝑀𝑃𝑎 and 𝜎𝑚
′′
= 224 𝑀𝑃𝑎 0.85T2 = → T2 = 311 N and T1 = 46.6 N
0.25 𝑚
Since 90° > 𝛽 > 𝛼; the failure will be due to fatigue. Therefore fatigue failure 2
criteria should be used. The next step is to obtain the moment diagram. The forces act in y and z directions
on the shaft. The reactions at bearings also act in these directions. It is needed to
𝑆𝑎′ 𝑆′ 1 1700⋅103 /𝑡 3970⋅103 /𝑡 1
+ 𝑆𝑚 = 𝑛 ➔ 173.9 .103 𝑃𝑎 + =2 analyze the forces on the shaft in x-z and x-y planes separately.
𝑆𝑒 𝑢𝑡 590.103 𝑃𝑎

METU – ME 307 Machine Elements I – Fall 2025

 9
x-z plane: x-y plane:
∑ 𝑀𝑂𝑧 = 0: −𝐶𝑦 (850) + 253(300) = 0
1
𝐹𝑧𝐴 = (𝑇1 + 𝑇2 ) 𝑐𝑜𝑠( 45𝜊 ) = 1.15(𝑇2 ) = 253 𝑁(𝑖𝑛-z direction)
√2 𝐶𝑦 = 89.1 𝑁

𝐹𝑧𝐵 = 320 𝑁 (in +z direction) ∑ 𝐹𝑦 = 0: −𝑂𝑦 + 253 − 𝐶𝑦 = 0

∑ 𝑀𝑂𝑦 = 0: 𝐶𝑧 (850) − 320(700) + 253(300) = 0 𝑂𝑦 = 163 𝑁

𝐶𝑧 = 174𝑁 The Shear and Bending Moment diagrams are as below:

300 400 150

∑ 𝐹𝑧 = 0: 𝑂𝑧 + 253 − 320 + 𝐶𝑧 = 0
y
𝑂𝑧 = −107𝑁
x
The shear and bending moment diagrams are as below:

300 400 150 Oy 253N Cy

x Shear
z 89.1N
Oz 253N 320N Cz -163N
Shear Moment
146N

-107N -48.9N.m
-174N
Torque on the shaft is:
Moment 26.3N.m Torque
33N.m
x
-32.1N.m

METU – ME 307 Machine Elements I – Fall 2025

 10
The maximum bending moment occurs at the position of pulley A. The critical A steady torsion and completely reversed bending is applied on the shaft. In other
section of the system is at A. Moment at the section A is a combination of words, the torsional stress has only mean component, and the bending stress has
moments on x-y and y-z planes: only alternating component.
𝑀𝐴 = √32. 12 + 48. 92 = 58.5 𝑁. 𝑚
𝑇 = 33 𝑁. 𝑚 Distortion energy theory:
Now that the force analysis is completed and the following fatigue analysis 𝐾𝑓,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 and 𝐾𝑓,𝑡𝑜𝑟𝑠𝑖𝑜𝑛 will be used as stress modifiers.
can be done. The Von Mises alternating stress is: (Equations 6-66,6-67 of our textbook)
Material is given as AISI 1030HR. HR stands for hot rolled steel. Table A-20
lists properties. Properties of the given material:

𝑆𝑢𝑡 = 470 𝑀𝑃𝑎 𝑆𝑦 = 260 𝑀𝑃𝑎

𝑆𝑒′ = 0.5 𝑆𝑢𝑡 = 235 𝑀𝑃𝑎

Modifying factors are already explained in detail in previous problems, so this 2 2

part is passed fast. 𝜎𝑎′ = √(𝐾𝑓,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 ⋅ 𝜎𝑎,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 + 𝐾𝑓,𝑎𝑥𝑖𝑎𝑙 ⋅ 𝜎𝑎,𝑎𝑥𝑖𝑎𝑙 ) + 3(𝐾𝑓𝑠,𝑡𝑜𝑟𝑠𝑖𝑜𝑛 𝜏𝑎 )

Endurance limit of shafts used in machine elements is found by finding the where, 𝜏𝑎 = 0 𝑎𝑛𝑑 𝜎𝑎,𝑎𝑥𝑖𝑎𝑙 = 0 → 𝜎𝑎′ = 𝐾𝑓,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝜎𝑎
modification factors:
′ 2 2
𝜎𝑚 = √(𝐾𝑓,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 ⋅ 𝜎𝑚,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 + 𝐾𝑓,𝑎𝑥𝑖𝑎𝑙 ⋅ 𝜎𝑚,𝑎𝑥𝑖𝑎𝑙 ) + 3(𝐾𝑓𝑠,𝑡𝑜𝑟𝑠𝑖𝑜𝑛 𝜏𝑚 )
Table 6-2 gives 𝛼 = 38.6 and 𝑏 = −0.650. Using Equation (6-18)
′
where, 𝜎𝑚,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 = 0, 𝜎𝑚,𝑎𝑥𝑖𝑎𝑙 = 0 → 𝜎𝑚 = √3 ⋅ 𝐾𝑓𝑠 ⋅ 𝜏𝑚
𝑘𝑎 = 𝑎(𝑆𝑢𝑡 )𝑏 = 38.6 ⋅ 470−0.650 (6-18)
= 0.707
For the critical differential element at A:
Since the diameter is not known, assume that it is in the range 7.62<d<51mm, 𝑑
𝑀𝐴 𝑐 1.6 𝑀𝐴 953.4𝑁𝑚
then let’s assume kb=0.85 as we did in previous question. 𝜎𝑎′= 𝐾𝑓,𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝜎𝑎 = 1.6 ⋅ ( ) = 1.6 ⋅ 2 4 = ⋅ 32 ⋅ 3 =
𝑘𝑐 = 1 as cycling stress is bending. (6-25) 𝐼 𝜋𝑑 𝜋 𝑑 𝑑3
𝑘𝑑 = 1 as no temperature is given 64
′
𝑇𝑐
𝑘𝑒 = 0.753 for 99.9% reliability 𝜎𝑚 = √3 ⋅ 1.3 ⋅ 𝜏𝑚 = √3 ⋅ 1.3 ⋅
𝐽
𝑑
√3 𝑇 378.4𝑁𝑚
𝑆𝑒 = 𝑘𝑎 𝑘𝑏 𝑘𝑐 𝑘𝑑 𝑘𝑒 𝑆𝑒′ = 0.707 ⋅ 0.85 ⋅ 1 ⋅ 1 ⋅ 0.753 ⋅ 0.5 ⋅ 470𝑀𝑃𝑎 𝜎𝑚′
= √3 ⋅ 1.3 ⋅ 𝑇 ⋅ 2 4 = ⋅ 1.3 ⋅ 16 ⋅ 3 =
𝜋𝑑 𝜋 𝑑 𝑑3
= 106.34𝑀𝑃𝑎 32
Note that √3 and 1.6 constants in their respective equations are not of equivalent
purpose. Former is from Von mises while latter is from stress modifiers.

METU – ME 307 Machine Elements I – Fall 2025

 11
Slope of the load line: Solution 4:
𝜎𝑎′ 953.4
tan−1 ( ′ ) = tan
−1
( ) = 68.35° a) The endurance limit of beam test spescimen Se’ is estimated as;
𝜎𝑚 378.4

Although the slope of the load line is high enough, it is better to check the 𝑆𝑒 ′ = 0.5(620) = 310𝑀𝑃𝑎
intersection point of the Yield line and the modified Goodman line: For the modifying endurance limit, modifying factors are to be determined.
Equation of the Yield line: 'a + 'm = Sy
From Equation (6-18) and Table 6-2, for forged steel
' ' 𝑘𝑎 = 54.9 ⋅ 620−0.758 = 0.454
Equation of the Goodman line: a + m = 1
Se Sut From (6-20), since the bar in question is bending while rotating, there is no need to
Intersection point is: calculate equivalent diameter. (it writes in pages 312-313);
𝑆𝑦 𝑘𝑏 = 1.51 ⋅ 160−0.157 = 0.68 d > 51 mm.
𝜎𝑎′ 𝑆𝑦 − 𝜎′𝑎 1− Note that free body diagram has not been drawn yet so estimated weak spots are
𝑆𝑢𝑡
+ = 1 → 𝜎𝑎′ = = 61.41𝑀𝑃𝑎 not given yet. However, we have no value other than 160mm and even for let’s say
𝑆𝑒 𝑆𝑢𝑡 1 1
−
𝑆𝑒 𝑆𝑢𝑡 200mm, this constant is still over 0.65 so this is reasonable.
𝑘𝑐 = 1 as the bar is bending while 𝑘𝑑 = 𝑘𝑒 = 𝑘𝑓 = 1 as nothing mentioned in the
′
𝜎𝑚 = 𝑆𝑦 − 𝜎𝑎′ = 198.59𝑀𝑃𝑎 question.
𝑆𝑒 = 𝑘𝑎 ⋅ 𝑘𝑏 ⋅ 𝑘𝑐 ⋅ 𝑘𝑑 ⋅ 𝑘𝑒 ⋅ 𝑆𝑒′ = 0.453 ⋅ 0.68 ⋅ 1 ⋅ 1 ⋅ 1 ⋅ 1 ⋅ 0.5 ⋅ 620
Slope of the intersection: = 95.70𝑀𝑃𝑎
𝜎𝑎′ 61.41
tan−1 ( ′ ) = tan
−1
( ) = 17.18° The next step is to estimate the bending stress. Note that, the mean stress due to
𝜎𝑚 198.59
fully reversed bending moment will be zero. The alternating stress due to bending
moment:
Since 17.18°<68.35°, failure is expected to be from fatigue. Thus, the Goodman
line determines the factor of safety.
𝜎𝑎′ 𝜎𝑚′
1
+ = 𝜋𝑑4 𝜋(160)4
𝑆𝑒 𝑆𝑢𝑡 𝑛 𝐼= = = (32.17)106 𝑚𝑚4
64 64
953.4𝑁𝑚 378.4𝑁𝑚 1 1
+ = =
𝑑3 ⋅ 106.34𝑀𝑃𝑎 𝑑3 ⋅ 470𝑀𝑃𝑎 𝑛 3

𝑑 ≥ 30.8𝑚𝑚
𝑘𝑏 = 1.24𝑑−0.107 = 0.859

The guessed 𝑘𝑏 value of 0.85 is not so far away from the obtained value of
0.859.

METU – ME 307 Machine Elements I – Fall 2025

 12
b) Using log S-log N diagram they can be determined.
𝐹 𝐹 From section The High-Cycle S-N Line of textbook, fatique strength can be
2 2 obtained from equations 6-12,6-13 and 6-14.
From figure 6-23, 𝑓 = 0.86.
𝛥 𝛥
For 𝜎1 = 200𝑀𝑃𝑎 𝐴𝐵𝐶 ≈ 𝐴𝐷 𝐸

𝑆𝑓 = 𝑎𝑁 𝑏
𝐹 𝐹
(𝑓𝑆𝑢𝑡 )2 (0.86 ⋅ 620)2
2 2 𝑎= = = 2970
𝑆𝑒 95.70

1 𝑓𝑆𝑢𝑡 1 0.86 ⋅ 620

𝑏 = − log ( ) = − log ( ) = −0.2486
3 𝑆𝑒 3 95.70
𝑀 𝑀
𝑀𝑜𝑚𝑒𝑛𝑡
Note that, we used base 10 logarithm

Figure 5
200 = 2970 ⋅ 𝑁 −0.2486 → 𝑁200 = 51678 𝑐𝑦𝑐𝑙𝑒𝑠

For 𝜎2 = 400 𝑀𝑃𝑎

1 400 = 2970 ⋅ 𝑁 −0.2486 → 𝑁400 = 3180 𝑐𝑦𝑐𝑙𝑒𝑠
𝑀 = (235)103 ( ) 250 = 29.4 ⋅ 106 𝑁 ⋅ 𝑚𝑚
2
Solution 5:
𝑑 160 The properties of the material: (Table A-20)
𝑐= = = 80𝑚𝑚
2 2 𝑆𝑢𝑡 = 620𝑀𝑃𝑎 𝑆𝑦 = 340 𝑀𝑃𝑎
𝑆𝑒′ = 0.5 𝑆𝑢𝑡 = 310 𝑀𝑃𝑎
𝑀𝑐 29.4 ⋅ 106 (80)
𝜎𝑎 = = = 73.1𝑀𝑃𝑎
𝐼 (32.17)106 The endurance limit modifying factors:
(6-18): k a = 0.59 for hot rolled material with Sut = 620MPa
The factor of safety is:
𝑘𝑏 = 0.85 given
95.70
𝑛= = 1.3 𝑘𝑐 = 1 nothing given
73.1 𝑘𝑑 = 1 nothing given
𝑘𝑒 = 0.814 for 99% reliability

𝑆𝑒 = 0.59 ⋅ 0.85 ⋅ 1 ⋅ 1 ⋅ 0.814 ⋅ 0.5 ⋅ 620 = 126.5 𝑀𝑃𝑎

METU – ME 307 Machine Elements I – Fall 2025

 13
To find the fatigue life of the part under the first loading, the constant life line is to
a) be considered by joining Sut on σa axis to the stress point (σa1, σm1) as shown in
First loading: Figure 6. That line passes through Sf1 on σa axis (where σm=0) i.e. the fatigue
The Modified Goodman approach (6-41) is used in this question. It is the second strength of first loading. Then, the equation of the constant life line is:
most conservative criterion after the Soderberg line.
𝜎𝑎1 𝜎𝑚1
According to the Manson’s rule(page 355-356), each cyclic loading has a + =1
𝑆𝑓1 𝑆𝑢𝑡
decreasing effect on the endurance limit of the part. Therefore, the endurance
limit should be recalculated after each period of loading. If the loading is in the So, Sf1 can be found by substituting 𝜎𝑎1 = 120 𝑀𝑃𝑎 and 𝜎𝑚1 = 80 𝑀𝑃𝑎,
finite life region (in the modified Goodman diagram for this question), the
120 80 126.5 620 − 80
fatigue strength of the part would be different than its endurance limit. By using + =1→ =
the modified Goodman diagram, its fatigue strength can be estimated. By this 𝑆𝑓1 620 𝑆𝑓1 620
fatigue strength its new endurance limit (after period of loading) can be 𝑆𝑓1 = 138 𝑀𝑃𝑎
obtained from the S-N diagram.
As seen in Figure 6, the mean stress of the loading is tensile, and the loading is Sf1 is greater than Se, so, this point corresponds to a finite life, N1, on the S-N
in the finite life region (above the Goodman line joining Se and Sut). diagram (Figure 7). The Manson’s rule says that to find the new endurance limit,
a Se1, of the part, a new line should be drawn on log(S)-log(N) curve joining
(103,0.8(Sut)) and (Nr1,Sf1) points, where Nr1 is the remaining life after the first
loading. This line is extended until 106 life (106,Se1). By this way, the damaged
Sy material Se1 is obtained. Note that 103 cycles is the starting point of the high-cycle
region (for all materials) and 106 is the limit for finite life for steels. The Manson’s
rule states no change in tensile strength of the part, i.e. (103,0.8(Sut)) point stays
same after each loading.
Sf2
( , )
a2 m2 An interesting relation given in section 6-8 states as steel alloys with higher
ultimate strength has smaller fraction of 103 cycle failure endurance limit, although
Sf1 ( , ) absolute value of endurance limit is stll higher. Note that on the S-N diagram, at
a1 m1
103 cycles the fatigue strength is taken as 0.8(Sut). 0.8 is an average value taken for
Se fatigue strength fraction, f (for high-cycle fatigue). Figure 6-23 in the 11th edition
of textbook gives more accurate value, it suggests to take f=0.86 for Sut=620 MPa.
For this problem, it is taken as f=0.8.
Sy Sut m
Figure 7 shows the reduction of endurance limit after each loading (Manson’s rule).
Figure 6 At first, the remaining life should be determined.
Equation of the S-N curve is:
𝑙𝑜𝑔( 𝑓𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 𝑆𝑒 )
𝑙𝑜𝑔( 𝑆) = 𝑙𝑜𝑔( 𝑓𝑆𝑢𝑡 ) − [𝑙𝑜𝑔( 103 ) − 𝑙𝑜𝑔( 𝑁)]
𝑙𝑜𝑔( 103 ) − 𝑙𝑜𝑔( 106 )

METU – ME 307 Machine Elements I – Fall 2025

 14
𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 𝑆𝑒 )
𝑙𝑜𝑔( 𝑆) = 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − [𝑙𝑜𝑔( 𝑁) − 3]
3

Lifetime, N1, corresponding to 138 MPa in the initial S-N diagram (Figure 7):

𝑆 = 𝑆𝑓1 = 138 𝑀𝑃𝑎 𝑎𝑛𝑑 𝑁 = 𝑁1

𝑙𝑜𝑔( 𝑆𝑓1 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 𝑙𝑜𝑔( 𝑁1 ) − 3
=
𝑙𝑜𝑔( 𝑆𝑒 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3
𝑙𝑜𝑔( 138) − 𝑙𝑜𝑔( 0.8(620)) 𝑙𝑜𝑔( 𝑁1 ) − 3
=
𝑙𝑜𝑔( 126.5) − 𝑙𝑜𝑔( 0.8(620)) 3
𝑁1 ≅ 644000 𝑐𝑦𝑐𝑙𝑒𝑠
The Remaining life for the part at 138 MPa loading is Figure 7
𝑁𝑟1 = 𝑁1 − 𝑛1 = 644000 − 200000 = 444000 𝑐𝑦𝑐𝑙𝑒𝑠 Second loading:
In this period, the mean and alternating stresses become 100MPa and 150MPa,
As mentioned before according to the Manson’s rule, the machine component respectively.
is damaged after the first loading, i.e. its endurance limit is decreased. The S-N As seen in Figure 6, the second loading is also in the finite life region (comparing
diagram now passes through (103,0.8(Sut)), (Nr1,Sf1) and (106,Se1). The new S- with the line joining Se1 and Sut). Similar to what is done for the first loading, the
N equation is: corresponding fatigue strength for the second loading, Sf2, is obtained from the
𝑙𝑜𝑔( 𝑓𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 𝑆𝑓1 ) modified Goodman diagram as:
𝑙𝑜𝑔( 𝑆) = 𝑙𝑜𝑔( 𝑓𝑆𝑢𝑡 ) − [𝑙𝑜𝑔( 103 ) − 𝑙𝑜𝑔( 𝑁)]
𝑙𝑜𝑔( 103 ) − 𝑙𝑜𝑔( 𝑁𝑟1 ) 𝜎𝑎2 150
𝑆𝑓2 = 𝜎𝑚2 =
𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 138) 1− 𝑆 100
𝑙𝑜𝑔( 𝑆) = 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − [3 − 𝑙𝑜𝑔( 𝑁)] 1−
3 − 𝑙𝑜𝑔( 444000) 𝑢𝑡 620
𝑆𝑓2 = 179 𝑀𝑃𝑎
The new endurance limit is:
𝑆 = 𝑆𝑒1 , 𝑁 = 106 To find the corresponding lifetime, N2, from the S-N diagram, this time life
𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 138) equation is used. It is the same as using log(S)-log(N) equation.
𝑙𝑜𝑔( 𝑆𝑒1 ) = 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − [3 − 𝑙𝑜𝑔( 106 )]
3 − 𝑙𝑜𝑔( 444000) The life equation is:
1
𝑙𝑜𝑔( 𝑆𝑒1 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3 𝑆𝑓2 𝑏 (𝑓(𝑆𝑢𝑡 ))2 (0.8(620))2
=− 𝑁2 = ( ) 𝑤ℎ𝑒𝑟𝑒 𝑎 = = = 2120
𝑙𝑜𝑔( 138) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3 − 𝑙𝑜𝑔( 444000) 𝑎 𝑆𝑒1 116
𝑙𝑜𝑔( 138) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 1 𝑓(𝑆𝑢𝑡 ) 1 0.8(620)
𝑙𝑜𝑔( 𝑆𝑒1 ) = 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − 3 𝑏 = − 𝑙𝑜𝑔 ( ) = − 𝑙𝑜𝑔 ( ) = −0.210
3 − 𝑙𝑜𝑔( 444000) 3 𝑆𝑒1 3 116
𝑆𝑒1 ≅ 116 𝑀𝑃𝑎 𝑁2 ≅ 130000 cycles

METU – ME 307 Machine Elements I – Fall 2025

 15
The Remaining life for the part at 179 MPa loading is b)
For a final completely reversed loading until failure, the fatigue strength is equal to
𝑁𝑟2 = 𝑁2 − 𝑛2 = 130000 − 50000 = 80000 𝑐𝑦𝑐𝑙𝑒𝑠 the applied stress because of zero mean stress.
𝑆𝑓3 = 𝜎𝑎3 = 200𝑀𝑃𝑎
Similar to what is done after the first loading, the new endurance limit after the From the last modified S-N diagram, the remaining life, N3, is found as:
second loading, Se2, can be obtained by re-plotting the S-N diagram. The new
S-N line passes through (103,0.8(Sut)), (Nr2,Sf2) and (106,Se2) as shown in Figure 𝑆 = 𝑆𝑓3 = 200𝑀𝑃𝑎 𝑎𝑛𝑑 𝑁 = 𝑁3
8.
The Final endurance limit is: 𝑙𝑜𝑔( 𝑆𝑓3 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 𝑙𝑜𝑔( 𝑁3 ) − 3
𝑆 = 𝑆𝑒2 𝑎𝑛𝑑 𝑁 = 106 =
𝑙𝑜𝑔( 𝑆𝑒2 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3
𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 𝑆𝑓2 )
𝑙𝑜𝑔( 𝑆𝑒2 ) = 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − [3 − 𝑙𝑜𝑔( 106 )]
3 − 𝑙𝑜𝑔( 𝑁𝑟2 ) 𝑙𝑜𝑔( 200) − 𝑙𝑜𝑔( 0.8(620)) 𝑙𝑜𝑔( 𝑁3 ) − 3
𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) − 𝑙𝑜𝑔( 179) =
𝑙𝑜𝑔( 𝑆𝑒2 ) = 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) + 3 𝑙𝑜𝑔( 99) − 𝑙𝑜𝑔( 0.8(620)) 3
3 − 𝑙𝑜𝑔( 80000)
𝑁3 ≅ 49000 𝑐𝑦𝑐𝑙𝑒𝑠
𝑆𝑒2 ≅ 99 𝑀𝑃𝑎
c)
The part has already completed 250000 cycles in the first and second loadings.
There is 100000 cycles left for third loading. The Maximum possible completely
reversed stress can be found by finding the limit stress for n3=N3.
From the last modified S-N diagram, the maximum completely reversed stress,
σa3max, is found as:
S = Sf 3 max = a3 max and N = N 3 = n 3 = 100000 cycles
log(a3 max ) − log(0.8Sut ) log(N3 ) − 3
=
log(Se2 ) − log(0.8Sut ) 3
5−3
log(a3 max ) = log(0.8(620)) +  log(99) − log(0.8(620))
3
a3 max  169 MPa

d)
The Miner’s rule does not consider the order of cumulative damage effect
introduced by different loadings. So, the order of loading is not important for The
Figure 8 Life reduction after second loading Miner’s rule. However, for The Manson’s rule, the order of application of the
loadings is taken into account. This is because The Manson’s rule takes the damage
of the part after each loading into account by considering the new damaged material

METU – ME 307 Machine Elements I – Fall 2025

 16
line after each loading. It can be a nice practice to solve the problem again by So, according to Miner’s rule:
changing the order of application of the loadings. By this way, it is possible to
see the order of damage effect. The final endurance limit would be 82 MPa, if 𝑛𝑖 𝑛1 𝑛2 𝑛3
∑ = + + =1
the second loading was applied firstly, and first was applied secondly. 5 MPa 𝑁𝑖 𝑁1 𝑁2 𝑁3
difference is because of the more damaging effect of high loading.
If the Miner’s rule is used, all lifetimes are found according to the initial S-N 200000 50000 𝑛3
diagram as: + + =1
644000 173000 98000
𝑆 = 𝑆𝑓1 = 138 𝑀𝑃𝑎 𝑎𝑛𝑑 𝑁 = 𝑁1
𝑛3 ≅ 39000 𝑐𝑦𝑐𝑙𝑒𝑠
𝑙𝑜𝑔( 𝑆𝑓1 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 𝑙𝑜𝑔( 𝑁1 ) − 3
= Although it does not consider the order of cumulative damage, the Miner’s rule
𝑙𝑜𝑔( 𝑆𝑒 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3
estimated a lower remaining life than the Manson’s rule does for the third loading.
𝑙𝑜𝑔( 138) − 𝑙𝑜𝑔( 0.8(620)) 𝑙𝑜𝑔( 𝑁1 ) − 3 This makes the Miner’s rule a more conservative approach for this problem. If the
= second loading had infinite life according to the initial S-N diagram, and finite life
𝑙𝑜𝑔( 126.5) − 𝑙𝑜𝑔( 0.8(620)) 3
according to the first modified S-N curve (of Manson’s rule), the Miner’s rule
would estimate life of the second loading as infinite, whereas the Manson’s rule
𝑁1 ≅ 644000 𝑐𝑦𝑐𝑙𝑒𝑠
would estimate a finite life since it considers reduced endurance limit.
𝑆 = 𝑆𝑓2 = 179𝑀𝑃𝑎 𝑎𝑛𝑑 𝑁 = 𝑁2
It is worth to note that, it is not possible to estimate the life of the part exactly.
These two estimation methods only give an idea to the engineer about the order of
𝑙𝑜𝑔( 𝑆𝑓2 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 𝑙𝑜𝑔( 𝑁2 ) − 3 magnitude of the remaining life. So, it is not possible to state which model gives
=
𝑙𝑜𝑔( 𝑆𝑒 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3 the best estimate, always.

𝑙𝑜𝑔( 179) − 𝑙𝑜𝑔( 0.8(620)) 𝑙𝑜𝑔( 𝑁2 ) − 3

=
𝑙𝑜𝑔( 126.5) − 𝑙𝑜𝑔( 0.8(620)) 3

𝑁2 ≅ 173000 𝑐𝑦𝑐𝑙𝑒𝑠

𝑆 = 𝑆𝑓3 = 200𝑀𝑃𝑎 𝑎𝑛𝑑 𝑁 = 𝑁3

𝑙𝑜𝑔( 𝑆𝑓3 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 𝑙𝑜𝑔( 𝑁3 ) − 3

=
𝑙𝑜𝑔( 𝑆𝑒 ) − 𝑙𝑜𝑔( 0.8𝑆𝑢𝑡 ) 3

𝑙𝑜𝑔( 200) − 𝑙𝑜𝑔( 0.8(620)) 𝑙𝑜𝑔( 𝑁3 ) − 3

=
𝑙𝑜𝑔( 126.5) − 𝑙𝑜𝑔( 0.8(620)) 3

𝑁1 ≅ 98000 𝑐𝑦𝑐𝑙𝑒𝑠

METU – ME 307 Machine Elements I – Fall 2025